Direct/Reverse Clutch Assembly: Reassembly
- If drum bushing is removed, install NEW bushing using hydraulic press with bushing driver, bushing extractor/installer and support plates. Install clutch drum hub bushing flush with hub surface.
- Using old bushing, press NEW bushing into hub until it is .067" (1.70 mm) below hub lip. Remove old bushing from hub bore with pliers. Install NEW seals on clutch drum and piston, with seal lips facing downward into drum.
- Completely lubricate piston assembly with ATF. Insert a 1 1/2-2" (38-51 mm) wide, thin (but flexible) plastic sheet around inside diameter of drum to protect piston seals during installation. Install piston assembly into drum with a twisting motion. Remove plastic sheet.
- Position spring plate on top of piston and springs on spring plate. Place retainer on top of springs. Compress drum assembly in press and install small circlip. Lubricate all clutch plates with ATF. Soak NEW plates in ATF for 15 minutes prior to installation
- Install 1 steel plate (external splines), then 1 lined plate (internal splines) into drum. Continue alternating steel and lined plates until all clutch plates are installed. Install pressure plate and clutch pack retaining circlip.
- Using a feeler gauge, measure clearance between clutch pack retaining circlip and pressure plate. The clearance should be within .081-.098" (2.05-2.50 mm). See Fig 1
.
Courtesy of VOLKSWAGEN UNITED STATES, INC.
- If clearance is incorrect, remove clutch pack circlip. Replace it with circlip of correct thickness to bring clearance within specifications. Circlips are available in various thicknesses from .059" (1.50 mm) to .098" (2.50 mm). Recheck clearance after installing replacement circlip.
- Assemble direct/reverse clutch with thrust washers and forward clutch onto oil pump. Blow compressed air into oil port and check that clutch piston audibly compresses clutch plates. When air pressure is released, ensure clutch plates release and piston returns to original position.